Replaceable Foam atop Mattress Spring Unit Contained within Constricting and Expanding Fabric Cover with Zipper which Opens and Closes Cover

ABSTRACT

This invention is a new mattress design. A replaceable foam unit containing the user&#39;s chosen firmness, or two different levels of firmness, one level being on the top of the unit, and the second firmness being on the bottom of the unit, sits atop a standard spring unit. The replaceable foam unit and standard spring unit are encased and held firmly together by a constricting and expanding fabric cover. A zipper on the cover allows for the cover to be opened, revealing the replaceable foam unit. The replaceable foam unit can then be flipped so that the second level of firmness faces upwards, and the user can experience a brand-new level of firmness. Or, the replaceable foam unit can be removed completely and replaced by a new replaceable foam unit, thus eliminating the need to replace the standard spring unit once disposal of a user&#39;s bed becomes necessary.

BACKGROUND OF INVENTION

The field of endeavor to which the invention pertains is that of improvement to the everyday mattress structure. The invention aims to improve comfortability of users over time, while decreasing the cost to replace a user's mattress, and reducing the number of disposed mattresses.

The level of firmness in a mattress which a user desires may change over time as that user ages. The invention is aimed to address that problem and is designed to allow individuals to change the firmness of their mattress without having to replace the entire mattress. This invention differs from the prior art because, when the mattress useful life is over or when a user requires a different firmness, the invention allows for replacement of one small aspect of the bed, that aspect being removable and replaceable foam with different levels of firmness, rather than replacement and disposal of the entire mattress.

This invention further considers responsible disposal of mattresses. Specific geographical areas may have mattress disposal regulations in place. To date, three states have developed and established mattress recycling laws: California, Rhode Island, and Connecticut. A Mattress Disposal Council has been developed by the mattress industry to operate recycling programs in states which have enacted these mattress recycling laws. The Mattress Disposal Council plays a role in implementing the collection process and helps establish recycling centers and programs in these states. The purpose of the legislation is to reduce illegal dumping, prevent unnecessary waste, and lessen the impact on the environment. State-wide programs like this aim to lower the almost 50,000 mattresses that are landfill-bound each day.

With the prior art, if a mattress has reached the end of its useful life, or if a user would like to replace the firmness of its mattress, the user is forced to dispose of the entire mattress. This invention will aim to decrease the number of complete disposed mattresses, inclusive of the spring coil unit, by allowing the replaceability of foam sitting atop a standard coil spring.

BRIEF SUMMARY OF THE INVENTION

The invention will include a standard spring unit (normal bed sizes, i.e. twin, queen, king, etc.) as the bottom of the full bed design. Sitting atop the standard spring unit will be a replaceable foam unit, variations of which will be further described under the Brief Description of the Drawings section. The replaceable foam will sit atop the standard spring unit, and is fastened to the standard string unit by the use of a fabric cover which encases the full mattress unit/design, which cover is closed and opened by use of a zipper. When the zipper is unfastened, the replaceable foam can be completely removed from the standard spring unit. The fabric will be made of a material which expands and constricts so that, once the zipper is fastened, the replaceable foam unit holds fast to the standard spring unit.

Different variations of the replaceable foam unit can be ordered at the user's desired level of firmness. Each piece of replaceable foam will consist of the user's choice of firmness. If the variation chosen by the user is of a type that contains two pieces of replaceable foam, then the second piece of replaceable foam can be a completely different firmness than the first. Thus, if a user has been using the top piece of the replaceable foam unit, and that piece of foam either wears out or the user's body changes so that the user prefers a different firmness, the user can change the firmness by unfastening the zipper and flipping the replaceable foam unit. The user would then be using the bottom piece of replaceable foam, which can be a different firmness than the top. The result will essentially be a brand-new bed without having to replace any part of the bed.

Once both pieces of replaceable foam are no longer desired, the user can order a new replaceable foam unit with two new levels of firmness. In addition, the user will only be disposing of the replaceable foam unit and not the entire spring unit. Only having to replace the foam will prove to be more cost effective to the user. In addition, only having to dispose of the replaceable foam, rather than the entire mattress, including the spring unit, is more environmentally friendly than the current prior art. Further, due to the manageable size and weight of the replaceable foam, it can be marketed so it is either sold in stores or a user could order online, and have the replaceable foam delivered directly to their door. In addition, the constricting and expanding fabric cover could be replaced as necessary based upon the size of the bed and replaceable foam unit being used.

Users can choose from different variations, and thus different price ranges, of the invention. For instance, a basic type bed can be made up of the spring unit and a 1″ to 1½″ single piece of replaceable foam. This basic bed is more financially affordable to a user due to the use of a single piece of replacement foam. As this type of basic bed would only contain a single piece of replacement foam, the user could only select a single firmness. The spring unit and single piece of replaceable foam on this basic bed would be contained within the constricting and expanding fabric cover, which cover is fastened closed by the zipper. The constricting and expanding fabric cover for this model would include a ½″ quilted cover, which lays directly on the single piece of replaceable foam, the purpose of which is to increase comfort on the single piece of replaceable foam.

A more durable and thus expensive model would consist of the spring unit on the bottom. The replaceable foam unit would consist of a 1½″ High Density (HD) Foam, encased by a piece of 1¼″ replaceable foam on each side of the HD Foam. Each piece of the replaceable foam can be a different level of firmness, as selected by the user. The HD Foam situated in the middle of each piece of replaceable foam would allow for a decreased thickness to each piece of replaceable foam, resulting in monetary savings to the user. The spring unit and replaceable foam unit would be contained within the constricting and expanding fabric cover, which closes by use of the zipper.

The most expensive model would not include HD Foam situated in the middle of each piece of replaceable foam. This model would consist of the spring unit on the bottom. The replaceable foam unit would consist of 2″ back to back pieces of replaceable foam, each of a different firmness. The spring unit and replaceable foam unit would be contained within the constructing and expanding fabric cover, which closes by use of the zipper.

The basic bed model would contain only one single piece of replaceable foam, and thus only one firmness. However, the user could choose which firmness it desired. Once the replaceable foam's useful life was over, the single piece of replaceable foam is removed from the unit by unzipping the constricting and expanding fabric cover and removing the single piece of replaceable foam. The replaceable foam could then be replaced by a new piece of replaceable foam, without having to replace the entire mattress unit. The constricting and expanding fabric cover can also be replaced as needed.

The more advanced models would provide an option for the use of two different levels of firmness, as selected by the user. When one piece of replaceable foam's useful life was over, or if the user wanted to experience a different firmness, the firmness can be changed by unzipping the constricting and expanding fabric cover, flipping the replaceable foam unit, and rezipping the constricting and expanding fabric cover to experience the other side of the replaceable foam unit, complete with a brand new firmness. The user would then have essentially a brand-new bed simply due to flipping the replaceable foam unit. Once the useful life of both sides of the replaceable foam unit had expired, or if the user desired a unit with different levels of firmness, the user can dispose of the replaceable foam without having to dispose of the spring unit. This is both environmentally friendly and cost effective to the user. The constricting and expanding fabric cover can also be replaced as needed.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects and advantages of the invention will be appreciated more fully from the following further description thereof, with reference to the accompanying drawings wherein:

Basic Bed Model

FIG. 1 illustrates a standard spring unit (in any of the standard bed sizes, i.e. twin, queen, king).

FIG. 2 illustrates the single piece of replaceable foam. The thickness of the single piece of replaceable foam can be increased or reduced based upon manufacturer determination. This figure suggests a thickness of 1″ to 1½″ for the single piece of replaceable foam. The user can choose its desired firmness (FIG. 7) for the single piece of replaceable foam.

FIG. 3 illustrates the entire mattress unit, which consists of the standard spring unit (FIG. 1) and the single piece of replaceable foam (FIG. 2).

FIG. 4 illustrates the constricting and expanding fabric cover which encases the mattress unit (FIG. 3). The cover can be opened and closed by use of a zipper (FIG. 5). A quilted cover (FIG. 6) will be attached and a part of the top of the constricting and expanding fabric cover, so that when the cover is closed the quilted cover sits directly on top of the single replaceable foam (FIG. 2). The constricting and expanding fabric cover will encase all elements of the mattress unit (FIG. 3), so that once zipped the mattress unit is sturdy and compact and acts as one unit. The zipper (FIG. 5) will operate to unzip the constricting and expanding fabric cover so that the single piece of replaceable foam (FIG. 2) can be removed from the standard spring unit (FIG. 1). FIG. 4 can be replaced by the user as necessary.

FIG. 5 illustrates a zipper that can open and close the constricting and expanding fabric cover (FIG. 4) which encases the complete mattress unit (FIG. 3). The zipper (FIG. 5) will operate to unzip the constricting and expanding fabric cover so that the single piece of replaceable foam (FIG. 2) can be removed from the standard spring unit (FIG. 1).

FIG. 6 illustrates a quilted cover that will be attached and a part of the top of the constricting and expanding fabric cover (FIG. 4), so that when the cover is closed, the quilted cover sits directly on top of the single replaceable foam (FIG. 2). The purpose of this quilted cover is for added comfort on the single piece of replaceable foam. This figure suggests a thickness of ½″ for the quilted cover.

FIG. 7 illustrates examples of the various levels of firmness that a user can choose for the single replaceable foam. The examples given are “Firm”, “Cushion Firm”, “Plush”, and “Ultra Plush.” Accordingly, a user could select any of these levels of firmness for the single piece of replaceable foam. The levels of firmness offered can be determined by the manufacturer. If a user decides that the useful life of the single replaceable foam (FIG. 2) has expired, or that it desires a new firmness, the single piece of replaceable foam can be removed by unzipping the constricting and expanding fabric cover (FIG. 4), removing the single piece of replaceable foam, replacing it with a new piece of replaceable foam, and rezipping the constricting and expanding fabric cover to bring FIGS. 1 and 2 into the complete compact mattress unit (FIG. 3).

High Density (HD) Foam Model

FIG. 1 illustrates a standard spring unit (in any of the standard bed sizes, i.e. twin, queen, king).

FIG. 2 illustrates the replaceable foam unit. This unit contains High Density (HD) Foam (FIG. 5.) fused and encased between a piece of replaceable foam on each side (FIGS. 3. and 4.). The thickness of each piece of replaceable foam (FIGS. 3 and 4) and HD Foam thickness (FIG. 5) can be increased or reduced based upon manufacturer determination. This figure suggests a thickness of 1¼″ for each piece of the replaceable foam (FIGS. 3 and 4) and a thickness of 1½″ for the HD Foam (FIG. 5). Each piece of replaceable foam can be its own firmness (FIG. 9) regardless of the firmness of the other piece of replaceable foam. For example, FIG. 3 could be “Firm” and 4 could be “Plush.” The user can choose which firmness to use by flipping the entire replaceable foam unit, utilizing the zipping mechanism (FIG. 8) to open the constricting and expanding fabric cover (FIG. 7). Using the example above, if the user would like to use the “Firm” side, it would place FIG. 3 facing upwards. If the user would like to use the “Plush” side, it would place FIG. 4 facing upwards.

FIG. 3. is a single piece of replaceable foam that it is fused to one side of the High Density (HD) Foam (FIG. 5). The thickness of FIG. 3 can be increased or reduced based upon manufacturer determination. This figure suggests a thickness of 1¼″ for FIG. 3 In addition, FIG. 3 can be its own firmness (FIG. 9) regardless of the firmness of FIG. 4.

FIG. 4. is a single piece of replaceable foam that it is fused to one side of the High Density (HD) Foam (FIG. 5). The thickness of FIG. 4 can be increased or reduced based upon manufacturer determination. This figure suggests a thickness of 1¼″ for FIG. 4. In addition, FIG. 4 can be its own firmness (FIG. 9) regardless of the firmness of FIG. 3.

FIG. 5. is a single piece of High Density (HD) Foam that is fused between FIGS. 3 and 4. The thickness of FIG. 5 can be increased or reduced based upon manufacturer determination. This figure suggests a thickness of 1½″ for FIG. 5.

FIG. 6 illustrates the entire mattress unit, which consists of the standard spring unit (FIG. 1) and replaceable foam unit (FIG. 2), which is encased by the constricting and expanding fabric in FIG. 7.

FIG. 7 illustrates the constricting and expanding fabric cover which encases the mattress unit (FIG. 3). The cover can be opened and closed by use of a zipper (FIG. 8). The constricting and expanding fabric cover will encase all elements of the mattress unit (FIG. 3), so that once zipped the mattress unit is sturdy and compact and acts as one unit. The zipper will operate to unzip the constricting and expanding fabric cover so that the replaceable foam unit (FIG. 2) can be removed from the standard spring unit (FIG. 1). FIG. 4 can be replaced by the user as necessary.

FIG. 8 illustrates a zipper that can open and close the constricting and expanding fabric cover (FIG. 4) which encases the complete mattress unit (FIG. 3). The zipper will operate to unzip the constricting and expanding fabric cover so that the replaceable foam unit (FIG. 2) can be removed from the standard spring unit (FIG. 1).

FIG. 9 illustrates examples of the different levels of firmness that a user can choose for each piece of replaceable foam (FIGS. 3 and 4). The examples given are “Firm”, “Cushion Firm”, “Plush”, and “Ultra Plush.” Accordingly, a user can select any of the offered levels of firmness for each piece of the replaceable foam (FIGS. 3 and 4). For example, FIG. 3 could be “Cushion Firm” and FIG. 4 could be “Ultra Plush”. The user could be using the FIG. 3 “Cushion Firm” side of the replaceable foam, and later decide to flip FIG. 2 Replaceable Foam Unit so that it can use the FIG. 4 “Ultra Plush” side of the replaceable foam. The firmness choices can be determined by the manufacturer. If a user decides that the useful life of the Replaceable Foam Unit (FIG. 2) has expired, or that it wants a new firmness, the Replaceable Foam Unit can be removed by unzipping (FIG. 8) the constricting and expanding fabric cover (FIG. 7), removing the Replaceable Foam Unit, replacing it with a new Replaceable Foam Unit, and rezipping the constricting and expanding fabric cover to bring FIGS. 1 and 2 into the complete compact mattress unit (FIG. 3).

Complete Foam Model

FIG. 1 illustrates a standard spring unit (in any of the standard bed sizes, i.e. twin, queen, king).

FIG. 2 illustrates the replaceable foam unit. This unit contains two pieces of replaceable foam fused together (FIGS. 3 and 4). The thickness of each piece of replaceable foam (FIGS. 3 and 4) can be increased or reduced based upon manufacturer determination. This figure suggests a thickness of 2″ for each piece of the replaceable foam (FIGS. 3 and 4). Each piece of replaceable foam can be its own firmness (FIG. 8) regardless of the firmness of the other piece of replaceable foam. For example, FIG. 3 could be “Firm” and 4 could be “Plush.” The user can choose which firmness to use by flipping the entire replaceable foam unit, utilizing the zipping mechanism (FIG. 7) to open the constricting and expanding fabric cover described in FIG. 6. Using the example above, if the user would like to use the “Firm” side, it would place FIG. 3 facing upwards. If the user would like to use the “Plush” side, it would place FIG. 4 facing upwards.

FIG. 3 is a single piece of replaceable foam that it is fused to another single piece of replaceable foam (FIG. 4). The thickness of FIG. 3 can be increased or reduced based upon manufacturer determination. This figure suggests a thickness of 2″ for FIG. 3 In addition, FIG. 3 can be its own firmness (FIG. 8) regardless of the firmness of FIG. 4.

FIG. 4 is a single piece of replaceable foam that it is fused to another single piece of replaceable foam (FIG. 3). The thickness of FIG. 4. can be increased or reduced based upon manufacturer determination. This figure suggests a thickness of 2″ for FIG. 4. In addition, FIG. 4 can be its own firmness (FIG. 8) regardless of the firmness of FIG. 3.

FIG. 5 illustrates the entire mattress unit, which consists of the standard spring unit (FIG. 1) and replaceable foam unit (FIG. 2), which is encased by the constricting and expanding fabric in FIG. 6.

FIG. 6 illustrates the constricting and expanding fabric cover which encases the mattress unit (FIG. 3). The cover can be opened and closed by use of a zipper (FIG. 7). The constricting and expanding fabric cover will encase all elements of the mattress unit (FIG. 3), so that once zipped the mattress unit is sturdy and compact and acts as one unit. The zipper will operate to unzip the constricting and expanding fabric cover so that the replaceable foam unit (FIG. 2) can be removed from the standard spring unit (FIG. 1). FIG. 4 can be replaced by the user as necessary.

FIG. 7 illustrates a zipper that can open and close the constricting and expanding fabric cover (FIG. 4) which encases the complete mattress unit (FIG. 3). The zipper will operate to unzip the constricting and expanding fabric cover so that the replaceable foam unit (FIG. 2) can be removed from the standard spring unit (FIG. 1).

FIG. 8 illustrates examples of the different levels of firmness that a user can choose for each piece of replaceable foam (FIGS. 3 and 4). The examples given are “Firm”, “Cushion Firm”, “Plush”, and “Ultra Plush.” Accordingly, a user can select any of the offered levels of firmness for each piece of the replaceable foam (FIGS. 3 and 4). For example, FIG. 3 could be “Cushion Firm” and FIG. 4 could be “Ultra Plush”. The user could be using the FIG. 3. “Cushion Firm” side of the replaceable foam, and later decide to flip FIG. 2. Replaceable Foam Unit so that it can use the FIG. 4 “Ultra Plush” side of the replaceable foam. The firmness choices can be determined by the manufacturer. If a user decides that the useful life of the Replaceable Foam Unit (FIG. 2) has expired, or that it wants a new firmness, the Replaceable Foam Unit can be removed by unzipping (FIG. 7) the constricting and expanding fabric cover (FIG. 6), removing the Replaceable Foam Unit, replacing it with a new Replaceable Foam Unit, and rezipping the constricting and expanding fabric cover to bring FIGS. 1 and 2 into the complete compact mattress unit (FIG. 3).

DETAILED DESCRIPTION OF THE INVENTION

The invention will include a standard spring unit as the bottom of the full bed design. Sitting atop the standard spring unit will be a replaceable foam unit, variations of which are described under the Brief Description of the Drawings section. The replaceable foam will sit atop the standard spring unit, and is fastened to the standard string unit by the use of a fabric cover which encases the full mattress unit/design, which cover is closed and opened by use of a zipper. When the zipper is unfastened, the replaceable foam will be visible. The fabric will be made of a material which expands and constricts so that, once the zipper is fastened, the replaceable foam unit holds fast to the standard spring unit.

The replaceable foam unit can be completely removed from the standard spring mattress unit and replaced as required by the user, without having to replace the standard spring mattress unit. In addition, a user can also choose a model that consists of two pieces of replaceable foam fused together, one piece of foam being comprised of one firmness and the second piece of foam being comprised of another firmness. To use the second firmness, the zipper on the expanding and constricting fabric cover can be unfastened to reveal the replaceable foam unit, and the entire replaceable foam unit can be flipped, so that the second firmness now faces upwards. Once the cover is rezipped, the bed will again come together as one unit.

This invention differs from the prior art because, when the mattress useful life is over or when a user requires a different firmness, the invention allows for replacement of one small aspect of the bed, that aspect being removable and replaceable foam with different levels of firmness, rather than replacement and disposal of the entire mattress. 

1. An apparatus for an individual to sleep or lay on, the apparatus comprising of a replaceable foam unit sitting atop a standard spring mattress unit, wherein the replaceable foam unit and spring mattress unit are encased in an expanding and constructing fabric cover, said cover having a zipper that, when zipped, fastens the replaceable foam unit firmly atop the mattress spring unit.
 2. Said replaceable foam unit described in claim 1 further comprising of either a single replaceable piece of foam consisting of one firmness, or two pieces of replaceable foam consisting of two levels of firmness, whether the two pieces of replaceable foam are fused back-to-back or fused and separated by a piece of High Density (HD) Foam.
 3. Said expanding and constricting fabric cover described in claim 1 may be comprised of additional padding that would lie atop the replaceable foam unit. 